BC Inflator Manual

Zeagle BCs
Buoyancy Control System Inspection and Service
and
Service Procedure for Power Inflators
Power Inflator
Applies to all Zeagle Buoyancy Control Systems and Zeagle Power
Inflators, p/n 112-1001 (standard) and p/n 112-2001 (high-flow)
Manual No. 147-2000 Rev C, copyright 2003
5
4
6
7
19
10
11
1
2
3
15
8
16
Hi-FLOW
connection used on
112-2001 Inflator
instead of item (12)
13
Find #
1
2*
3
4
5*
6
7
8*
9
10*
DESCRIPTION
DUMP BUTTON
O-RING
SPRING
MOUTHPIECE
LABEL STICKER
SCREW
INFLATE BUTTON
SPRING
BODY
O-RING
PART NUMBER
112-1003
*
115-4019
112-1008
*
115-4018
112-1004
342-0220-VH
112-1002
*
Find #
11
12
13*
14*
15*
16*
17
19
20*
21
112-1010
115-4015
115-6001
111-4001
347-0380
PART NUMBER
112-1007
115-4016
*
*
112-1005
Manual No. 147-2000 Revision C
DESCRIPTION
DUMP VALVE
QD FITTING
O-RING
O-RING
INFLATE SHAFT
VALVE INSERT ASSEMBLY
QD FITTING, HIGH FLOW
PIN
TIE WRAP, (NOT SHOWN) ( QTY: 2)
LOCTITE 380 (3 grams)
Note: Service Kit P/N 145-1000 includes all parts marked with a *. O-rings availible only in sevice kit.
PARTS LIST FOR 2002 VERSION OF ZEAGLE POWER INFLATORS
P/N 112-1001 (Standard) & P/N 112-2001 (High-Flow)
14
9
13
12
17
Service Procedure for the Zeagle Power Inflator p/n 112-1001
IMPORTANT NOTE: The Zeagle 112-1001 Power Inflator was improved in 2002. Changes to the
Valve Insert Assembly (p/n 112-1010), the Inflate Shaft (p/n 112-1005) and the Button Spring (p/n
115-4019) improve the Zeagle Power Inflator’s feel, durability and resistance to sand contamination.
Although the parts have changed, the part numbers have remained the same. This is because the
parts have the same fit and function and are fully backwards compatible with all Zeagle 112-1001
Inflators made. The new parts are contained in the Service Kit (p/n 145-1000). Removing the old
parts and replacing them with the new parts in the kit will transform an older 112-1001 Power
Inflator to the latest version. The Inflator Button Sticker on the newer inflators and in the kits, has
been changed from a red to a white background color to visually identify the latest version of Zeagle
112-1001 Power Inflators. Follow the included exploded view diagram of this inflator when using
this instruction sheet. Read this procedure thoroughly, to familiarize yourself with the steps required
before proceeding. See the last page of this manual for a cutaway view showing the internal differences between the older and revised inflators.
BCD Inflators are gas control devices that are subjected to free floating sand, grit and salt deposits.
It is not unusual for an Inflator to develop a hissing leak when particles jamb the valve. It is standard practice to overhaul all diving gas control devices at least annually and even more often with
severe use such as rental or training. Zeagle strongly recommends that BCDs and Inflators be
serviced by a trained technician at least annually. Standard service for the BCD inflator includes the
installation of the service kit p/n 145-1000.
!
! Warning ! Never install a new Valve Core (Schrader Valve) into a used Valve Insert Assembly
(16). The plastic threads on the Valve Insert Assembly are only intended to be engaged once at the
factory. Always use a complete new Valve Insert Assembly (16) from Zeagle when overhauling a
Zeagle 112-1001 Inflator.
Tools & Items Needed
- Zeagle Inflator Service Kit p/n 145-1000
- 3/16" Allen Wrench (at least 3” long)
- 1/4" Allen Wrench
- Small Philips Screwdriver
- 5/16" Nut Driver
- 1/2" Wrench
- Pliers
- Pick
- Loctite 380 Thread Sealant (for ABS Plastic) (Zeagle p/n 347-0380)
- Lubricating Grease (LTI Christo-Lube 111® recommended) (Zeagle p/n 347-0111)
- Clean lint-free rag.
1. Disassembly
1.1
1.2
1.3
1.4
1.5
1.6
Remove the Quick Disconnect fitting (12) from the body (9) with a 1/2" wrench
Remove and discard the O-ring (13) from the QD fitting.
Use a 1/4" Allen wrench to loosen the valve insert assembly (16).
Use pliers to pull the valve insert assembly out of the body (9).
Discard the valve insert assembly (16).
Carefully remove and discard the label sticker (5) from the inflate button (7) with a sharp pick.
Note: If the old label sticker is red and the replacement sticker in your service kit is white, you
will be upgrading the Power Inflator during your servicing.
1.7 Use a small Phillips screwdriver to remove the screw (6) from the button. While removing the
screw, use a 5/16" nut driver to hold the inflate shaft (15). Remove the button spring
Note: If the old label sticker you removed was red and the replacement sticker in your service kit
is white, the old style curved washer spring will be discarded.
1.8 Discard the O-ring (14) and the inflate shaft (15).
1.9 Use a 3/16" Allen wrench (at least 3” long) inserted through the body (9) into the hex of the dump
valve (11) to loosen and remove the dump valve (11) from the dump button (1).
1.10 Remove and discard the O-rings (10 and 2).
2. Cleaning and Inspection
2.1 Clean the parts that can be re-used (1,3,4,6,7,8,9,11 and 12) in warm soapy water.
2.2 Rinse and blow all parts dry.
2.3 Look closely at plastic parts for wear and cracks. Look particularly closely at areas under stress
from threading and clamping. Discard any part that shows signs of cracking.
3. Re-assembly
3.1
3.2
3.4
3.5
3.6
3.7
3.8
Open Service Kit # 145-1000. Remove and inspect all parts in the kit.
Lubricate all loose kit O-rings with Lubricating Grease. (LTI Christo-Lube 111® recommended)
Install O-ring (10) onto the dump valve (11). Install O-ring (2) onto the dump button (1).
Lubricate the threads on the dump valve (11) with grease.
Place the dump valve (11) onto the end of a long 3/16" Allen wrench.
Insert the dump valve into the body (9) through the BC inflator hose end.
Install the spring (wide end first) over the dump valve from the dump button end. Turn the spring
onto the shaft.
3.9 Screw the dump valve (11) into the dump button (1). Stop turning as soon as you feel the
shoulders of the two parts meet.
3.11 Install the smallest O-ring in the kit (14) on the new inflate shaft (15) that also came in the kit
(sometimes this O-ring will come pre-installed on the shaft).
3.12 Use the 5/16" nut driver to push the new inflate shaft (15) with its new O-ring, into the body (9)
3.13 Use a small Phillips screwdriver to install the screw (6) through the inflate button, into the new
inflate shaft (15). Hold the inflate shaft from turning by using the 5/16" nut driver. The screw is
turning new threads into the inflate shaft so some force will be required.
3.14 Just tighten the screw (6) snugly. Stop turning when you feel the shoulders of the parts meet.
3.15 Install the new white sticker (5) onto the inflate button (7).
3.16 Turn the body so that the white sticker (5) is facing down. Drop the new coil spring (8) into the
threaded hole of the body where the valve insert assembly will threaded. It will fall over the new
longer inflate shaft stem (15).
3.17 Lubricate the threads and O-rings (in place) on the valve insert assembly (16) that
came with the service kit. Look at the end of the valve insert where the valve core is preinstalled. Notice that the valve core lies in a slight recess. This recess is where the coil spring
must fit when the valve insert is installed into the body.
3.18 Push the valve insert assembly (16) into the body (9). Use the 1/4" Allen wrench to tighten the
valve insert snugly into the body. Stop turning the insert when you feel the shoulders of the
parts meet. Look into the body at the coiled spring (3). If it is not sitting evenly in the recess of
the valve insert, use a finger or a small screwdriver to push the spring into position. Work the
inflate button several times and observe the action of the parts for correct fit and operation
Correct any problems seen.
3.19 Lubricate and install the new O-ring (13) onto the QD fitting (12).
3.20 Important: Place one drop of Loctite 380 Thread Sealant (Zeagle p/n 347-0380) onto the outer
two threads of the QD fitting (12)
3.21 install the QD fitting into the body (9). Tighten the fitting snuggly with a 1/2" wrench. Stop
turning the fitting when you see and feel the shoulders of the parts meet.
4. Testing
4.1 Push and release both the inflate and deflate buttons. Check for smooth operation. Look into
the opening where the corrugated hose will attach. There should be a very slight gap between
the end of the inflate shaft (15) and the valve core tip of the valve insert assembly (16). No gap
may produce slow leaks of intermediate pressure air into the BCD later on.
4.2 Before hooking the Power Inflator up to the corrugated BC hose, install it on a pressurized BC
inflator hose.
4.3 Immerse the entire Power Inflator under water for at least 5 minutes. Look for leaks. Replace
necessary parts if any leaks are found.
4.4 Install the Power Inflator onto the corrugated hose of the BCD, and to a pressurized inflator
hose.
4.5 Check the buttons for proper operation and feel. Fully inflate the BCD and again submerge the
Power Inflator underwater for 5 minutes. Look for leaks. Replace necessary parts if any leaks
are found.
Buoyancy Control System Inspection and Service
This procedure applies to all Zeagle Systems Buoyancy Control Systems.
Note: For normal recreational usage, an annual inspection interval is recommended. For severe
service (military, search and recovery, training, etc.), inspection intervals should be decreased to
six months.
Before beginning Inspection:
Dry the BC thoroughly before inspection so that the condition of all materials can be seen clearly.
Conduct the inspection under brightly-lit conditions so that the details of the materials can be
closely inspected.
Inspection:
Inflate the BC fully and inspect the condition of all seams and panels. Look very closely at the
areas in the lower part of the BC subject to wear when the BC is dragged across rough surfaces.
Examine all seams for torn material and threads. While inflating the vest fully check the operation of the over-pressurization valve for release and re-sealing.
Deflate the BC and examine areas where the tank bands attach to the vest section of the BC.
Look closely around all grommets for material separation and tearing. While deflating the BC,
check all dump valves (oral inflator, shoulder wire pull dump and bottom dump valve) for proper
operation and resealing. Inspect all zippers for missing pull-tabs and teeth. Examine the stitching holding the zipper in place. Inspect all cylinder band buckles for cracks. Replace entire Band
Assembly if any cracks are found. Check the entire band assembly for tears, missing Velcro and
broken stitching. Inspect the corrugated hose for tears, pinholes, cracking, or deterioration of the
material. Replace the hose if defects are found.
If the BC has a Ripcord® type weight release system, don the BC and pull the Ripcord® to
check for the proper dropping of the weights. There should be a lead clamp on the middle area
of the cord that prevents the cord from being pulled completely out of the BC. Examine the
Ripcord® cable. If the Ripcord® cable comes completely free from the BC the entire BC must
be returned to Zeagle for repair. Examine the weight drop pocket area of the BC. Check the
grommets and white hang loops for wear and deterioration. For directions on re-threading the
Ripcord® System, refer to the Zeagle BC Owner’s manual or go to the Product Support section
of the Zeagle web site at www.zeagle.com.
Check the Power Inflator Valve for proper operation and leaks. To overhaul the Power Inflator
see the Service Procedure for Power Inflators.
Fully inflate the BC and set it aside for 20 minutes. After that time, the bladder should still be
firmly inflated. If the BC has deflated, inflate the BC again and listen closely for leak points. If
leakage is too slow to be heard, immerse the BC in water to locate leak(s).
Note: If during this BC Inspection any problems are found that you (the Authorized Zeagle
Service Technician) cannot repair, contact Customer Service in the US at (813) 782-5568.
Order Form (sample)
This is a copy of the Service Parts Request Form. The actual form is a three-page carbon copy that is available
by request from Zeagle Customer Service. If you do not have any forms on hand, you may photocopy this page
and use it to receive warranty parts credit.
Service Order / Parts Request Form
This form must be used by the Service Center
for ANY Warranty Servicing
You MUST contact Zeagle for an RA
Number to receive any Warranty Credit
Zeagle Service Center:
City, State (Prov), Country:
Phone / E-mail:
Date Serviced:
37150 Chancey Rd.
Zephyrhills, FL 33541
(813) 782-5568
Fax (813) 782-5569
www.zeagle.com
Technician Name (PRINT):
Technician Number:
Customer Name:
Address:
City, State (Prov), Country:
Phone / E-mail:
RA # (call Zeagle): __________________
1st Stage Model: _____________________
Serial #: ____________________
2nd Stage Model: _____________________
Serial #: ____________________
BCD Model: ______________________ ____________________
Comments:
Part # Installed
Description of Part
145-1000
112-1010
Inflator Service Kit
Valve Insert Assembly
Warranty Item? Y/N
Note: If a body or housing is replaced, note the new serial # in "Description of Part"
Customer Price
Total:
I am the original (first) owner of this equipment being serviced. Yes ____ No _____
Customer's Signature: _____________________________________ Date: _____________
The customer must provide proof of original ownership (receipts, etc.) before any "in Warranty" service can be performed.
Service Center: Be sure this form is completely filled out, signed by the customer and returned to Zeagle for credit on warranty parts.
37150 Chancey Road
Zephyrhills, Florida 33541
U. S. A.
Zeagle Scuba, the Zeagle symbol, Ripcord and LT1 Christo-Lube are trademarks of Zeagle Systems Inc.
All other names are trademarks of their respective owners. All products subject to change without
notice.
Zeagle Web Site www.zeagle.com
Contact Zeagle Technical Services by E-mail at [email protected]
© 2003 Zeagle Systems Inc.
Printed in USA
Part Number for this Manual (p/n 147-2000 Rev C)